Ingersoll-Rand 125-200 HP/90-160 KW Maintenance Schedule, Maintenance Records, Special Note

Page 31

4.0SCHEDULED PREVENTATIVE MAINTENANCE

4.1MAINTENANCE SCHEDULE

THE MAINTENANCE SCHEDULE SPECIFIES ALL RECOMMENDED MAINTENANCE REQUIRED TO KEEP THE COMPRESSOR IN GOOD OPERATING CONDITION. SERVICE AT THE INTERVAL LISTED OR AFTER THAT

NUMBER OF RUNNING HOURS, WHICHEVER OCCURS FIRST.

Action

Part or Item

 

 

Running

 

Time Interval (whichever comes first)

 

 

Hours

 

1 Week 1 Mo. 3 Mo.

6 Mo. Yearly 2 Years

 

 

 

 

 

 

 

 

Inspect

Coolant level

 

 

Weekly

 

x

 

 

 

 

 

 

 

 

 

Inspect

Discharge temperature (air)

 

 

Weekly

 

x

 

 

 

 

 

 

 

 

 

Inspect

Separator element differential

 

 

Weekly

 

x

 

Inspect

Air filter Delta P (at full load)

 

 

Weekly

 

x

 

Inspect

Oil filter Delta P

 

 

Weekly

 

x

 

 

 

 

 

 

 

 

 

Replace

Coolant filter*

 

150

 

x (initial change only)

 

Check

Temperature sensor

 

1000

 

x

 

Replace

Food grade coolant (when used)

 

1000

 

 

x

Inspect

Hoses

 

1200

 

x

 

Replace

Coolant filter*

 

2000

 

 

x (subsequent changes)

Analysis

Coolant

 

2000

 

See Section 4.15

x

Analysis

Vibration

 

2000

 

See Section 4.15

x

Clean

Separator scavenge screen and orifice

4000

 

 

x

Clean

Cooler cores**

 

4000

 

 

x

Replace

Air filter*

 

4000

 

 

x

 

 

 

 

 

 

 

 

Replace

Separator element*

*See special note.

 

 

Replace

Ultra Coolant*

 

8000

 

 

x

Inspect

Starter contactors

 

8000

 

 

x

 

 

 

 

 

 

 

Service

Drive motor lubrication

 

 

 

 

See Section 4.10.

 

 

 

 

 

 

 

 

*In very clean operating environments and where inlet filter is changed at the above prescribed intervals. In extremely dirty environments change coolant, filters, and separator elements more frequently.

**Clean cooler cores if discharge air temperature is excessive or if unit shutdown occurs on high air temperature.

4.2 MAINTENANCE RECORDS

It is very important that you, the owner, keep accurate and detailed records of all maintenance work you, or the Ingersoll-Rand Distributor or Air Center perform on your compressor. This includes but is not limited to coolant filter, separator, inlet air filter and so forth. This information must be kept by you, the owner, should you require warranty service work by your Ingersoll-Rand Distributor or Air Center. Maintenance record sheets are located at the back of this manual.

4.3 MAINTENANCE PROCEDURES

Before starting any maintenance, be certain the following is heeded.

1.Read Safety Instructions.

2.Use correct tools.

3.Have recommended spares on hand.

SPECIAL NOTE:

Replace separator element when the separator differential pressure ( P) reaches three times the initial pressure drop or a maximum pressure differential of 12 psi (.8 bar) at full load or if the Intellisys warning CHANGE SEPARATOR ELEMENT is displayed. See Section 3.9.

29

Image 31
Contents Form Apdd 738B Phone CCN 80440415 REV BAIR Compressor Group Bonded Warranty & Registered Start UP This unit was purchased from Rotary Screw AIR CompressorTable of Contents Safety and Warnings Safety Shutdown Decals Lift HereViewed From Rear DecalsCompressor Package Data Tools InspectionIngersoll-Rand Company Davidson, North Carolina Unpacking and HandlingPerformance will be affected VentilationFoundation Requirements Never elevate the compressor unitDischarge Piping with Aftercooler ROTARY-RECIP in Parallel Moisture Content of Compressed AIRPiping Do not use the compressor to support the discharge pipeRotary TWO Compressor System Electrical InstallationDrive Motor Rotation CheckIntellisys Operating Instructions Electrical InstallationHasp Lever TAG KEY Lock FAN MotorOutdoor Sheltered Installation 1 Typical Outdoor Sheltered Installation Intellisys Controller IntellisysStop Power on LightIntellisys Controls Emergency Stop StartCurrent Status Display ScreenCurrent Status Items Intellisys DiagramOperator Panel Flow FigureOperator Setpoints Main MenuOptions Items Range Step Unit OptionsOptions Sensor Calibration Alarm HistorySensor Calibration Items Clock Functions Alarm History ItemsIntegral Sequencing Range Step Unit Integral SequencingStatus Main Menu Reset Alarm Main Menu AlarmsPage Number of Running HOURS, Whichever Occurs First Maintenance ScheduleMaintenance Records Maintenance ProceduresElements Inlet AIR FilterCoolant Filter 200 HP/132-160 KW Requires 2 ElementsHot coolant can cause severe injury CoolantItems Required Coolant DrainCoolant ProcedureSeparator Tank Scavenge SCREEN/ORIFICE Tools Required 125/200 HP Coolant Separator ElementTank cover bolt torque values Recommended Bolt Tightening Cross PatternCoolant Coolers Cooler Cores CleaningAftercooler Aftercooler CleaningAftercooler Relubrication amount Lubricant Amount Motor Frame Size Grams Motor LubricationHazardous voltage. Can cause severe injury or death Motor Bearing Maintenance Stored UnitsMotor Lubrication Recommended Motor GreaseController Removal Long Term Storage GeneralIntellisys Removal ToolsRemoval InstallationCoolant Sampling Procedure Coolant HosesCooling FAN Motor AIR Cooled Compressors Design TemperaturesGeneral System Information Coolant CoolerElectrical System Compressed AIR System The air system is composedCOOLANT/AIR Separation System OperationAutomatic Unloaded Start STAR-DELTA Type StarterStepper Motor Inlet Control Capacity ControlAutomatic START/STOP Control Modulation onlyFirst Some Examples of Operation SecondExample Remote START/STOP Troubleshooting Chart Troubleshooting Chart Separator DELTA-P Solenoid Power Outage Restart OptionSequencer LOW AmbientModbus Remote LOAD/UNLOADReference Drawings Electrical Schematic Star DeltaPage Foundation Plan 125-150 HP/90-110KW Aircooled Single Stage Foundation Plan 125-150 HP/90-110 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage Foundation Plan 200 HP/132-160 KW Aircooled Single Stage REV C REV C Foundation Plan 200 HP/132-160 KW Watercooled Single Stage Foundation Plan 200 HP/132-160 KW Watercooled Single Stage 100-150 HP/75-110 KW TWO Stage Foundation Plan AircooledFoundation Plan Aircooled 100-150 HP/75-110 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan Aircooled 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED Foundation Plan -WATERCOOLED 100-150 HP/75-110 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Foundation Plan -WATERCOOLED 200 HP/132-160 KW TWO Stage Flow Schematic Aircooled Single Stage Page Flow Schematic Watercooled 90F 32C Single Stage Page Flow Schematic Watercooled 115F 46 Single Stage Page Flow Schematic AIR-COOLED TWO Stage Page Flow Schematic Watercooled 90F 32C TWO Stage Page Flow Schematic Watercooled 115F 46C TWO Stage Page Typical System Flow Diagrams Typical System Flow DiagramTypical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Typical System Flow Diagrams Parameter Concentration Frequency of Analysis ScaleCorrosion FoulingPage Alkalinity ppm Temperature FTotal dissolved solids ppm Hardness ppmMaintenance Record Maintenance Record Maintenance Record Maintenance Record